More work on the under carriage

Meant to take an image of the sleeve on the transfer box.

To quote from Ashcroft Transmission website:

"The hole that supports the head of the intermediate pin in the LT230 casing is prone to wearing, and the pin elongates the hole so that it is out of round. This can lead to a transfer case whine, and an oil leak. Using our CNC lathe, we turn a stepped bush from EN24T steel. We mount the casing in our CNC mill, and machine an oversized hole on the correct centre and press the steel bush into the housing."

Added the transfer box gear selector rods. Fitted with new plastic bushes and clips. Also the breathers with new copper washers.

Fitted new rear bump stops. One thing to note is that there is a ridge that is offset on the back. This needs to be matched correctly into the chassis.

Fitted with new flanged bolts, nuts and washers.

Fitted a PCT adjustable towbar.

Needed a bigger torque wrench to fit the M16 bolts.

 

Fuel tank all fitted with guard and hoses with new clips.

Transmission Rebuilding

Ordered some grease for the inner of the clutch release bearing. Workshop manual stated that it needs to have Molybdenum Sulphide.

Clean up the transmission brake drum and the compressor. Cleaned up the pads and inner brake surface with brake/clutch cleaner.

Thankfully the bolt alignment ensures that it can only be fitted in the correct orientation.

Went to fit the speedo worm gear. However, noticed that the stud had been removed by Ashcroft Transmissions

Will have to order a new stud. Also, need to renew the O rings. 

Spent some time trying to identify this bracket. Turns out that this mounts to the bell housing to keep various cables under the chassis tidy.

Could not resist upgrading to a heavy duty clutch release bearing.

It weighs an absolute ton and feels the business.

Dismantled the transfer box lever mechanism. Renewing the O rings and various bushes.

Transfer Box Fitted

Used the crane to hoist up the transfer box. Mounted the main gearbox on a number of wooden beams to raise enough to allow the awkward alignment of the transfer box. Then strapped the gearbox to the bench with some ratchet straps.

Applied some EP oil to the splines and surface of the transfer box seal. The guide pins were really useful.

Hoisting up.

Aligning.

Originally there were 4 bolts and 2 threaded studs. However, the transfer box returned from Ashcrofts with a threaded stud in one of the holes where an original bolt would have been fitted. The stud was not for removing so used that and fitted with a new washer and nut. All torqued up nicely.

Bell Housing

Fitted the bell housing and release bearing support.

Gearbox looking mint.

Bell housing added.

 

Release bearing support fitted.

Gearbox and Transfer box fitting

Got the main gearbox and transfer box back on the bench. Had to use the crane. There was no way I would be able to lift them directly off the floor onto the bench.

Transfer box looking like new.

Gearbox lifted up too.

Splines looking immaculate.

Ready for mating to the transfer box.

Also cleaned up the main gearbox lever housing. Planning on cleaning up the transfer box lever housing too once spare O rings and bushes have arrived.

Sedimentor Fitting

Fitting the mounting bracket and the sedimentor to the left hand side of the chassis just behind the wheel.

Location of the holes to mount the bracket.

Sedimentor fitted.

Suspect that the blanking plugs of the sedimentor may need to be swapped around. Thinking that both the entry and exit fuel lines will access the sedimentor from the left.

Fuel Tank Mounting Bracket

Fitted a new mounting bracket for the fuel tank. Noticed that the tabs on the bracket need to be folded over the bolt heads and around the chassis. This helps to ensure that when the tank is fitted the bolts do not get pushed out and do not rotate when fastening.

Image from the workshop manual.

Bracket before bending the tabs.

Bending the tabs over the bolt heads.

Fitting the bracket to the chassis.

Fuel Tank Sender Fitted

Fitted a new sender to the fuel tank.

This is part number AMR1495

Inside of the tank is looking nice and clean.

Sender fitted with new rubber seal and locking ring.

Aluminium Housing Cleaning

Took the bell housing, flywheel housing and coolant housings to "Soda Blast" in Bristol.

Must say that they have come up really well!!!

Front of bell housing.

Rear of bell housing.

Front of flywheel housing.

Rear of flywheel housing.

Coolant housings.